Electronic display assembly having thermal cooling plate and optional convective air cooling loop

ABSTRACT

Disclosed herein is an electronic display assembly including a backlight that is positioned to illuminate a liquid crystal display, and a novel cooling mechanism in the form of a thermal plate that is located and configured to transfer heat from the backlight to a thermally conductive housing of the electronic display assembly. The thermal plate is preferably placed in conductive thermal communication with the backlight and with the thermally conductive housing for this purpose. One or more air flow apertures may pass through the thermal plate. A convective cooling loop may also be provided, which cooling loop may include a fan that is located to move cooling air over the thermal plate and/or though one or more apertures in the thermal plate. Both a top and bottom thermal plate may be employed in some exemplary embodiments.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.13/954,469, filed on Jul. 30, 2013, now U.S. Pat. No. 9,313,917, issuedon Apr. 12, 2016. U.S. application Ser. No. 13/954,469 is a continuationof U.S. application Ser. No. 12/630,469, filed on Dec. 3, 2009, now U.S.Pat. No. 8,497,972. application Ser. No. 12/630,469 is a continuation inpart of U.S. application Ser. No. 12/618,104, filed Nov. 14, 2009, nowU.S. Pat. No. 8,310,824 issued on Nov. 13, 2012. All aforementionedapplications are hereby incorporated by reference in their entirety asif fully cited herein

FIELD OF THE INVENTIVE CONCEPT

The exemplary embodiments herein are directed towards an electronicdisplay having a thermal plate with an optional cooling loop forconductive and convective cooling.

BACKGROUND OF THE INVENTIVE FIELD

Electronic displays are now being used for not only indoor entertainmentpurposes, but are now being utilized for indoor and outdooradvertising/informational purposes. For example, liquid crystal displays(LCDs), plasma displays, light emitting diode (LED),electroluminescence, light-emitting polymers, organic light emittingdiode displays (OLEDs) and many other displays can now be used todisplay information and advertising materials to consumers in locationsoutside of their own home or within airports, arenas, transit stations,stadiums, restaurants/bars, gas station pumps, billboards, and evenmoving displays on the tops of automobiles or on the sides of trucks.

The rapid development of these displays has allowed users to mount themin a variety of locations that were not previously available. Further,the popularity of high definition (HD) television has increased thedemand for larger and brighter displays, especially large displays whichare capable of producing HD video. The highly competitive field ofconsumer advertising has also increased the demand for large,attention-grabbing, bright displays

When used outdoors, high ambient temperatures and solar loading canpresent several thermal-regulatory issues. When a display is exposed todirect sunlight this can increase the temperature of the displaydramatically due to the solar loading of the front display surface dueto the radiative heat of the sun. It has been found, that moving airthrough a gap between the exterior transparent plate and the imageassembly can sometimes provide adequate cooling of the display assembly.Further, when producing an image with a display that has been placed indirect sunlight, the illumination of the display assembly must overcomethe high ambient light levels. Thus, the display must be very bright andsometimes produce high levels of illumination which can generate highlevels of heat coming from the image assembly (or backlight ifnecessary). This heat must be removed from the display or it may damagethe electrical assemblies. If an LCD is used, high internal temperaturescan cause the liquid crystal material to malfunction and may producenoticeable failures on the image. LEDs can degrade in performance andefficiency when exposed to high temperatures. Other technologies (OLED,light-emitting polymers, etc.) can also malfunction when exposed to hightemperatures.

SUMMARY OF THE EXEMPLARY EMBODIMENTS

An exemplary embodiment may contain a thermal plate which can transferheat from the image assembly to the housing of the display and into theambient air through convection. A transparent plate assembly may be usedwhich can provide the front surface for a narrow channel of cooling airwhich may be directed between the transparent plate assembly and theimage assembly. The cooling air can also pass over the thermal plate inorder to aid in cooling the thermal plate. In some embodiments, thethermal plate may run the entire length of the image assembly and maycontain several apertures which allow cooling air to pass through theplate. When using an LCD display with an LED backlight, the heatgenerated by the LED backlight can also be transferred through thethermal plate and into the display housing as well as the cooling air.The display housing can be sealed and does not require an inlet ofambient air so that the display can be used in environments which havecontaminates (dust, grease, pollen, dirt, leaves, garbage, water,insects, smoke, salt, fumes, etc.) present within the ambient air.

The exemplary embodiments herein are not intended to be exhaustive or tounnecessarily limit the scope of the invention. The exemplaryembodiments were chosen and described in order to explain the principlesso that others skilled in the art may practice the embodiments. Havingshown and described exemplary embodiments, those skilled in the art willrealize that many variations and modifications may be made to affect thedescribed invention. Many of those variations and modifications willprovide the same result and fall within the spirit of the exemplaryembodiments. It is the intention, therefore, to limit the embodimentsonly as indicated by the scope of the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

In addition to the features mentioned above, other aspects of thepresent invention will be readily apparent from the followingdescriptions of the drawings and exemplary embodiments, wherein likereference numerals across the several views refer to identical orequivalent features, and wherein:

FIG. 1 provides a perspective view of an embodiment which uses twodisplays in a back-to-back arrangement;

FIG. 2 provides a perspective sectional view of the embodiment shown inFIG. 1 and showing the air flow through the housing;

FIG. 3 provides a detailed view of insert A from FIG. 2;

FIG. 4 provides a detailed view of insert B from FIG. 2; and

FIG. 5 provides a perspective view of one embodiment for an exemplarythermal plate.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENT(S)

FIG. 1 provides a perspective view of one embodiment which uses adual-display assembly 100. In a preferred embodiment, the housing 115and the door frames 105 and 110 would provide an environmentally-sealedenclosure to protect the internal components of the display assembly 100from damage due to dust, grease, pollen, dirt, leaves, garbage, water,insects, smoke, salt, fumes, etc. Although shown with two displaysback-to-back, this setup is not required. A single display assembly canbe used as well. The exemplary embodiments herein are capable of coolingthe display without having to ingest ambient air (although this can beused if desired).

FIG. 2 provides a sectional view of the embodiment shown in FIG. 1. Thisfigure illustrates the air flow (dashed lines) through the housing 115.A transparent plate assembly 200 may be placed in front of the imageassembly 30. For this embodiment, the transparent plate assembly 200 maybe contained within the door frame 110 which is then attached to thehousing 115. However, in other embodiments the door frame would not be aseparate piece but would simply be provided by the housing. In theseembodiments, the housing 115 would extend around the transparent plateassembly 200 without the need for a separate door frame 110.

The image assembly 30 will vary depending on the type of display beingused with the particular embodiment. For example, if an LCD display isbeing used the image assembly 30 will typically comprise several layersincluding: a backlight, front and rear polarizers, liquid crystalmaterial sandwiched between two transparent plates, anelectrically-conductive layer, and possibly additionalpolarizing/anti-reflective layers. An OLED display on the other hand,may comprise: a cathode, emissive layer, conductive layer, and an anode.As mentioned above, embodiments can be practiced with any type of flatpanel display, including but not limited to: LCD, OLED, plasma, lightemitting polymer (LEP) and organic electro luminescence (OEL) displays.

The transparent plate assembly 200 can be made of a variety of materialsand may have one or more layers. Various transparent glasses, plastics,or composite materials may be used to produce the transparent plateassembly 200. However, in an exemplary embodiment the transparent plateassembly 200 would be made of glass and even more preferably would bemade of two or more plates of glass which are laminated together withindex-matching optical adhesive. Further, an exemplary embodiment wouldalso contain a polarizer on the transparent plate assembly 200.Preferably, the polarizer would be placed on the inside surface of theglass assembly and would also contain an anti-reflective (AR) layer. Ithas been found that adding the polarizer layer on the transparent plateassembly 200 can reduce reflections and also reduce the solar loading onthe image assembly 30.

A channel 550 may be defined by the rear surface of the transparentplate assembly 200 and the front surface of the image assembly 30. Thechannel 550 has an inlet opening 551 and exit opening 552. In thedual-display embodiment, the display assembly 100 is mostly symmetrical,having a second channel 560, second image assembly 31, and secondtransparent plate assembly 201 on the opposing side of the dual-displayassembly 100.

A fan 500 may be used to draw air through the channels 560 and 550 andcirculate it though the housing 115. While being circulated through thehousing 115, the air may transfer heat to the interior walls of thehousing 115 where it can then be transferred from the housing 115 to theambient air. In an exemplary embodiment, the fan 500 may be mounted on aseparating plate 300 which divides the interior cavity of the housing115 into upper and lower portions. It has been found that this type ofsetup may provide an area of high pressure in one portion and lowpressure in the other portion which can further drive the movement ofair throughout the cavity. For example, in an exemplary embodiment theseparating plate 300 may be used to create an area of high pressure inthe top portion (near the inlet opening 551 of the channel 550) and anarea of low pressure in the bottom portion (near the exit opening 552 ofthe channel 550) which may drive the air to flow through the channel 550and return to the fan 500.

It has been found that solar loading of the front surface of the imageassembly 31 and 30 can occur when the display assembly 100 is used indirect sunlight. This solar loading can result in a heat buildup on thefront surface of the image assembly 30 and 31. By using the channels 560and 550, this heat can be removed from the image assemblies andtransferred to the display housing 115 (and optionally the door frame110) where it can be transferred to the ambient air through convection.

Thus, in an exemplary embodiment, the thermal conductivity of thedisplay housing 115 and door frame 110 would be high. Thus, metals arean exemplary material for constructing the display housing 115 and doorframe 110. Preferably, there would be a low level of thermal resistivitybetween the inner and outer surfaces of the housing 115 and door frame110 so that heat can be effectively transferred to the surroundingambient air. Thermoelectric modules (not shown) may also be used inorder to cool the interior of the display housing 115. Fins or heatsinks (not shown) may also be placed on the interior or exterior of thehousing 115 and/or door frame 110 to increase the ability to absorb heatfrom the interior of the display and transfer it to the ambientsurroundings.

FIG. 3 provides a detailed view of insert A from FIG. 2. In thisembodiment, an LED edge-lit LCD is used as the image assembly 30. Anarray of LEDs 620 are provided along the edge of the LCD in order toprovide a source of illumination. When used in outdoor environments, theillumination of the image assembly 30 must compete with the ambientlight levels and sometimes with direct sunlight. In order to remainvisible (and preferably very bright and clear), the illumination comingfrom the image assembly 30 must of course be brighter than thesurroundings. Thus, when using an LED backlit LCD, the LEDs 620 mustproduce a high level of luminance which can sometimes cause the LEDs 620to generate a substantial amount of heat.

The various optical properties of the light which is output from an LEDare typically dependant upon temperature. Thus, as the temperature ofthe LED array 620 varies, the optical properties of the light may varyas well. These variations are undesirable because they may alter theimage (color saturation, color temperature, brightness, contrast, etc.)that is being produced by the image assembly 30. Therefore, in anexemplary embodiment the heat that is produced by the image assembly 30(in this case an edge-lit LED LCD) may be removed to maintain the imageassembly 30 at a consistent temperature. This helps to ensure imageaccuracy as well as avoids damage or a shortened lifetime due to hightemperatures.

Although described here in relation to an LED edge-lit LCD, it should benoted that these thermal effects are also observed when using othertypes of image assemblies, including but not limited to: plasmadisplays, direct backlit LCDs, light emitting diode (LED) displays,electroluminescence, light-emitting polymers, and organic light emittingdiode displays (OLEDs). Thus, embodiments can be designed which wouldremove heat from these image assemblies as well.

In the embodiment shown in FIG. 3, the LED array 620 is placed inthermal communication with the door frame 110 and optionally the housing115 as well. Once the heat has been transferred to the door frame 110(and optionally the housing 115) it may be transferred to the ambientsurroundings through convection. In an exemplary embodiment, a thermalplate 675 may be used to place the LED array 620 in thermalcommunication with the door frame 110 (and optionally the housing 115).An exemplary thermal plate 675 would have an ‘L-shaped’ cross-sectioncontaining a first and second portion. The first portion would have adistal end 710 and the second portion would have a distal end 715 wherethe two portions are joined at their proximal ends 712 (see FIGS. 4 and5) in order to form the ‘L’ shape. (See FIG. 5 for more information onan exemplary thermal plate).

For the embodiment shown in FIG. 3, heat from the LED array 620 istransferred to the distal end 710 of the first portion of the thermalplate 675 where it may be transferred by conduction to the distal end715 of the second portion. Once the heat has been transferred to thedistal end 715 of the second portion then it may be transferred to thedoor frame 110. In an exemplary embodiment, the door frame 110 wouldalso be in thermal communication with the housing 115 so that heat canalso be transferred (preferably by conduction) to the housing 115 andfurther dissipate to the surroundings. As discussed above, in otherembodiments the door frame 110 would not be a separate piece but wouldsimply be provided by the housing 115. In these embodiments, the housing115 would extend around the transparent plate assembly 200 without theneed for a separate door frame 110. Thus, with these embodiments thethermal plate 675 would simply be in thermal communication with thehousing 115.

An exemplary thermal plate 675 would also be placed in the path ofcooling air 600, which aids in the transfer of heat from the LED array620. As the heat moves from the distal end 710 of the first portion tothe distal end 715 of the second portion, a plurality of apertures (seeFIG. 5) may be located on the thermal plate 675 to allow the cooling air600 to pass through the thermal plate 675 and traverse through channel550. Optionally, the cooling air 600 can also pass over the surfaces ofthe thermal plate which oppose the LED array (see element 755 of FIG.5). The cooling air 600 may be used to cause convective heat transferfrom the thermal plate 675. A heat sink 650 may be used to place the LEDarray 620 and the thermal plate 675 in thermal communication with oneanother.

Specifically, when used with edge-lit LCDs, the exemplary embodimentshave been found to be very effective in removing heat from thebacklight. Edge-lit backlights concentrate a large amount of the heatalong the edges of the image assembly 30. Because most of the heat isconcentrated along the edges, it can be effectively removed by anexemplary thermal plate 675.

FIG. 4 provides a detailed view of insert B from FIG. 2. Here, a similarconfiguration as shown in FIG. 3 may be used. For this embodiment, theLED array 620 may be placed in thermal communication with the door frame110 and optionally the housing 115 as well. Once the heat has beentransferred to the door frame 110 (and optionally the housing 115) itmay be transferred to the ambient surroundings through convection. In anexemplary embodiment, a thermal plate 675 may be used to place the LEDarray 620 in thermal communication with the door frame 110 (andoptionally the housing 115).

For the embodiment shown in FIG. 4, heat from the LED array 620 istransferred to the distal end 710 of the first portion of the thermalplate 675 where it may be transferred by conduction to the distal end715 of the second portion. Once the heat has been transferred to thedistal end 715 of the second portion then it may be transferred to thedoor frame 110 where it can then be transferred to the ambientsurroundings. In an exemplary embodiment, the door frame 110 would alsobe in thermal communication with the housing 115 so that heat can alsobe transferred (preferably by conduction) to the housing 115 and furtherdissipate to the surroundings. As discussed above, in other embodimentsthe door frame 110 would not be a separate piece but would simply beprovided by the housing 115. In these embodiments, the housing 115 wouldextend around the transparent plate assembly 200 without the need for aseparate door frame 110. Thus, with these embodiments the thermal plate675 would simply be in thermal communication with the housing 115.

An exemplary thermal plate 675 would also be placed in the path ofcooling air 600, which aids in the transfer of heat from the LED array620 (or image assembly 30—if an edge-lit LCD is not being used). As theheat moves from the distal end 710 of the first portion to the distalend 715 of the second portion, a plurality of apertures (see FIG. 5) maybe located on the thermal plate 675 to allow the cooling air 600 to passthrough the thermal plate 675 and traverse through channel 550.Optionally, the cooling air 600 can also pass over the surfaces of thethermal plate which oppose the LED array (see element 755 of FIG. 5).The cooling air 600 may be used to cause convective heat transfer fromthe thermal plate 675. A heat sink 650 may be used to place the LEDarray 620 and the thermal plate 675 in thermal communication with oneanother.

FIG. 5 provides a perspective view of an exemplary embodiment for athermal plate 675. As discussed above, an exemplary thermal plate 675would have an ‘L-shaped’ cross-section containing a first and secondportion. The first portion would have a distal end 710 and the secondportion would have a distal end 715 where the two portions are joined attheir proximal ends 712 in order to form the ‘L’ shape.

The LED array (or any other heat-producing portion of an image assembly30) may be in thermal communication with surface 750 of the thermalplate 675. This heat may be transferred to the opposing side of thethermal plate 755 where cooling air (dashed lines) may pass over thesurface 750 in order to remove the heat by convection. The remainingheat (indicated by the arrows 900) can also travel towards the proximalend 712 of the first portion where a plurality of apertures 700 allowthe cooling air (dashed lines) to pass through the thermal plate 675 andfurther extract heat. Any heat that is still remaining (indicated by thearrows 900) continues to travel along the thermal plate 675 towards thedistal end 715 of the second portion which is preferably in thermalcommunication with the door frame 110 (or the housing 115 or both thehousing 115 and the door frame 110). The remaining heat is thentransferred to the various portions of the door frame 110 and optionallythe housing 115 so that it can be removed by convection into thesurrounding ambient air.

Some embodiments may not utilize the apertures 700 in the thermal plate675. Alternatively, these designs may use a plurality of smaller thermalplates 675 (those which do not run the entire length of the imageassembly) and allow spacing in between these smaller plates for thecooling air to pass through.

The door frames 110 and 105, thermal plate(s) 675, and housing 115 wouldpreferably be made out of a thermally conductive material and preferablywith a low thermal resistance. An exemplary material may be metal, andpreferably formed sheet metal, but could also be cast and/or machined orinjection molded. Any thermally-conductive materials can be used.

Again, while some embodiments have been described herein with referenceto back-to-back displays, the various teachings can be used with singledisplay setups as well. In an exemplary embodiment, the thermal plateand cooling loop arrangement can be used in combination with a singledisplay setup. Alternatively, the thermal plate could be used with orwithout the cooling air loop, in a single or dual display setup.

Exemplary embodiments provide display assemblies which may be mounted inareas which are subject to high ambient temperatures and even directsunlight and will be able to dissipate the solar load as well as theheat produced by the image assembly and/or backlight (if necessary). Theexemplary embodiments herein are capable of cooling the display withouthaving to ingest ambient air (although this can be used if desired)which can be especially useful in environments which containcontaminates in the ambient air.

While certain embodiments are described in detail above, the scope ofthe invention is not to be considered limited by such disclosure, andmodifications are possible without departing from the spirit of theinvention as evidenced by the following claims.

What is claimed is:
 1. An electronic display assembly comprising: athermally conductive housing; a liquid crystal display positioned withinthe thermally conductive housing; a backlight positioned to illuminatethe liquid crystal display; a thermal plate in conductive thermalcommunication with the backlight and with the thermally conductivehousing; and one or more air flow apertures that pass through thethermal plate.
 2. The electronic display assembly of claim 1 wherein:the thermal plate is positioned between an edge of the liquid crystaldisplay and the housing.
 3. The electronic display assembly of claim 1wherein: the backlight is a LED backlight.
 4. The electronic displayassembly of claim 1 further comprising: a fan located within thethermally conductive housing and configured to cause a flow of coolingair through the one or more apertures in the thermal plate.
 5. Theelectronic display assembly of claim 4 wherein: the one or moreapertures are oriented horizontally relative to the ground when theelectronic display is in a typical viewing orientation, while the flowpath of the cooling air extends vertically through the one or moreapertures.
 6. The electronic display assembly of claim 1 wherein: thethermal plate is located and configured to transfer heat from thebacklight to the thermally conductive housing.
 7. The electronic displayassembly of claim 4 wherein: the thermal plate is located and configuredto accept heat from the backlight, and is positioned for convectiveremoval of said heat by the flow of cooling air.
 8. The electronicdisplay assembly of claim 1 wherein: the thermal plate and housing aremetallic.
 9. An electronic display assembly comprising: a thermallyconductive housing having a front portion which faces an intendedobserver; a liquid crystal display positioned within the thermallyconductive housing; a backlight positioned behind the liquid crystaldisplay; a thermal plate in contact with the backlight and with thethermally conductive housing; and one or more air flow apertures thatpass through the thermal plate.
 10. The electronic display assembly ofclaim 9 wherein: the thermal plate is located and configured to absorbheat from the backlight and to transfer the heat forwardly towards thefront portion of the thermally conductive housing.
 11. The electronicdisplay assembly of claim 9 wherein: the thermal plate contains aportion which is oriented substantially horizontally, and is positionedabove both the backlight and the liquid crystal display.
 12. Theelectronic display assembly of claim 9 wherein: the backlight is a LEDbacklight.
 13. The electronic display assembly of claim 9 wherein: thethermal plate is positioned in a cooling air path that travels over andthrough the thermal plate.
 14. The electronic display assembly of claim13 further comprising: a fan located within the thermally conductivehousing and configured to cause cooling air to flow within the coolingair path.
 15. The electronic display assembly of claim 13 wherein: thecooling air path travels through the apertures within the plate.
 16. Anelectronic display assembly comprising: a thermally conductive housing;a liquid crystal display positioned within the thermally conductivehousing; a backlight having a top portion and a bottom portion andpositioned to backlight the liquid crystal display; a top thermal platecontacting the top portion of the backlight; and a bottom thermal platecontacting the bottom portion of the backlight; wherein the top thermalplate and the bottom thermal plate are located and configured totransfer heat from the backlight to the thermally conductive housing.17. The electronic display assembly of claim 16 further comprising: oneor more fans located within the thermally conductive housing andconfigured to cause a flow of cooling air that will pass through one ormore apertures in the top thermal plate and the bottom thermal plate.18. The electronic display assembly of claim 17 further comprising: avertically oriented channel through the housing, the channel forming acooling air pathway between the thermal plates.
 19. The electronicdisplay assembly of claim 16 wherein: the top thermal plate spans acrossthe backlight and the liquid crystal display and is located above thebacklight and the liquid crystal display; and the bottom thermal platespans across the backlight and the liquid crystal display and is locatedbelow the backlight and the liquid crystal display.
 20. The electronicdisplay assembly of claim 16 further comprising: one or more aperturespassing through the top thermal plate; one or more apertures passingthrough the bottom thermal plate; and a fan located within the thermallyconductive housing and configured to cause a flow of cooling air to passthrough the aperture(s) in the top thermal plate and the aperture(s) inthe bottom thermal plate.